Cable hanger production system and production method

ABSTRACT

A cable hanger which can alternately and continuously form a Z-winding spiral and an S-winding spiral using a hanger wire. A hanger wire is supplied from one end of a housing and sent out from the other end thereof. A plurality of spiral forming dice are accommodated in a cylindrical space in the housing. Each spiral forming die includes a bottom face forming a shape corresponding to a curvature of a spiral on a plane intersecting with an axis at right angles between an inner peripheral face of the housing and the bottom face, a Z-winding wall face forming a shape corresponding to a pitch of the Z-winding spiral inclined with respect to the plane, and an S-winding wall face forming a shape corresponding to a pitch of the S-winding spiral. The S-and Z-winding wall faces intersect each other at a central portion of the spiral forming die.

TECHNICAL FIELD

The present invention relates to a production system and a productionmethod of a cable hanger used for bundling optical fiber cables such asoptical collecting drop cables or wires such as various cables into onebetween electric poles.

BACKGROUND ART

Conventionally, a cable hanger is used for bundling wires such asoptical fiber cables into one between electric poles. As a cable hangerof this kind, there is one called spiral hanger formed into a spiralshape (for example, see U.S. Pat. No. 5,727,777).

The cable hanger that is called spiral hanger is formed by winding ahanger wire into a coil shape in a constant direction. When a hung wireis extended between electric poles, one end of the cable hanger importsan end of the hung wire therein, the cable hanger is kept rotating inone direction along the spiral shape, the hung wire is taken therein andwith this, the cable hanger is supported.

As the spiral cable hanger, there is proposed a cable hanger havinglargely enhanced operability.

This cable hanger is formed by alternately and continuously forming aZ-winding spiral and an S-winding spiral along an axis via a switchingpart instead of forming a spiral shape into a constant direction (seeJapanese Patent Application Laid-open No. 2005-168284).

Therefore, when a hung wire is extended between electric poles, thecable hanger is disposed along the hung wire and then, any of switchingparts of the cable hanger imports the hung wire therein, and it is keptrotating in one direction (e.g., rotated leftward) until it reaches anext switching part as it is. If it reaches the next switching part, theswitching part imports the hung wire therein, and it is kept rotating inone direction (e.g., rotated rightward) until it reaches the nextswitching part as it is. By carrying out such a taking-in operation overthe entire length of the hung wire, the hung wire can be taken in thecable hanger swiftly.

DISCLOSURE OF THE INVENTION

However, because the cable hanger must be formed by alternately andcontinuously forming the Z-winding spiral and the S-winding spiral usingthe hanger wire, a production system suitable for this has not yet beenproposed.

The present invention has been achieved to solve the above problems, andit is an object of the invention to provide a production system and aproduction method of a cable hanger capable of alternately andcontinuously forming the Z-winding spiral and the S-winding spiral usinga hanger wire.

In a cable hanger production system according to a first aspect of thepresent invention, a Z-winding spiral and an S-winding spiral arealternately and continuously formed along an axis via a switching part.A hanger wire is supplied from one end of a housing and sent out fromthe other end thereof. A plurality of spiral forming dice areaccommodated in a cylindrical space in the housing such that the spiralforming dice are adjacent to each other and can rotate independentlyfrom each other. Each spiral forming die includes a bottom face forminga shape corresponding to a curvature of a spiral on a plane intersectingwith an axis at right angles between an inner peripheral face of thehousing and the bottom face, a Z-winding wall face forming a shapecorresponding to a pitch of the Z-winding spiral inclined with respectto the plane, and an S-winding wall face forming a shape correspondingto a pitch of the S-winding spiral. The Z-winding wall face and theS-winding wall face intersect with each other at a central portion ofthe spiral forming die in its longitudinal direction. A regionsandwiched between the Z-winding wall face and the S-winding wall faceis constituted by the bottom face in front of and behind theintersection.

In a cable hanger production system according to a second aspect of theinvention, a Z-winding spiral and an S-winding spiral are alternatelyand continuously formed along an axis via a switching part, theproduction system comprises a wire processing device including a housinghaving a cylindrical space in which a hanger wire is supplied from oneend of the housing and the hanger wire is sent out from the other endthereof, and a plurality of spiral forming dice which are accommodatedin the cylindrical space of the housing in adjacent to one another suchthat the spiral forming dice can be rotated by a motor independentlyfrom each other; and a wire supply device which is disposed in front ofthe wire processing device for supplying the hanger wire toward the oneend of the wire processing device; the spiral forming dice arepositioned by shifting from positions for forming the Z-winding spiralor S-winding spiral to positions for forming the S-winding spiral orZ-winding spiral by simultaneously rotating second and subsequent spiralforming dice with respect to the first spiral forming die as a referenceas counted from the one end of the wire processing device, and bystopping the spiral forming dice from a front side; and a rotationvelocity of each of the spiral forming dice by the motor is set to sucha value that the spiral forming die rotates through a rotation anglerequired for shifting from the forming position of the Z-winding spiralor S-winding spiral to the forming position of the S-winding spiral orZ-winding spiral while the hanger wire supplied by the wire supplydevice moves from a front end to a rear end of the spiral forming dice.

In a production method according to a third aspect of the invention forforming a cable hanger in which a Z-winding spiral and an S-windingspiral are alternately and continuously formed along an axis via aswitching part, a hanger wire is supplied from one end of a housing andsent out from the other end thereof, a plurality of spiral forming diceare accommodated in a cylindrical space of the housing such that thespiral forming dice are adjacent to each other and they can rotateindependently from each other, the spiral forming dice are used; each ofthe spiral forming dice includes a bottom face forming a shapecorresponding to a curvature of the spiral on a plane intersecting withthe axis at right angles between inner peripheral face of the housingand the bottom face, a Z-winding wall face forming a shape correspondingto a pitch of the Z-winding spiral which is inclined with respect to theplane, and an S-winding wall face forming a shape corresponding to apitch of the S-winding spiral, the Z-winding wall face and the S-windingwall face intersect with each other at a central portion of the spiralforming die in a longitudinal direction thereof, and a region sandwichedbetween the Z-winding wall face and the S-winding wall face isconstituted by the bottom face, in the method; after a first step ofinserting the hanger wire along the intersections into each of thespiral forming dice positioned at a location where the intersections arearranged along the axial direction is executed, the hanger wire issupplied from the one end and in this state, and second to fifth stepsare repeated by predetermined times; the second step of positioning thespiral forming dice at locations where the Z-winding wall faces orS-winding wall faces are sequentially connected to each other; the thirdstep of keeping the spiral forming dice in their positioned state and offorming the Z-winding spiral or S-winding spiral having a predeterminednumber of windings; the fourth step of shifting the spiral forming diceto locations where the S-winding wall faces or Z-winding wall faces aresequentially connected to each other; and the fifth step of keeping thespiral forming dice in their positioned state and of forming theS-winding spiral or Z-winding spiral having a predetermined number ofwindings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic plan view showing the entire structure of a cablehanger production system according to the present invention.

FIG. 2 are schematic perspective views of spiral forming dice which iscombined as a wire processing device, and are explanatory diagramssequentially showing rotating position of spiral forming dice when aZ-winding spiral is formed.

FIG. 3 is a front view of a stationary spiral forming die.

FIG. 4 is a plan view of the stationary spiral forming die.

FIG. 5 are a schematic plan view (a), a schematic front view (b), aschematic bottom view (c) and a schematic rear view (d) of spiralforming dice combined as a wire processing device, and show positions ofthe spiral forming dice when passing through a hanger wire.

FIG. 6 are a schematic plan view (a), a schematic front view (b), aschematic bottom view (c) and a schematic rear view (d) of the spiralforming dice combined as the wire processing device, and show positionsof the spiral forming dice when forming a Z-winding spiral.

FIG. 7 are a schematic plan view (a), a schematic front view (b), aschematic bottom view (c) and a schematic rear view (d) of the spiralforming dice combined as the wire processing device, and show positionsof the spiral forming dice rotated from the positions shown in FIG. 6through 90° for forming an S-winding spiral.

FIG. 8 are a schematic plan view (a), a schematic front view (b), aschematic bottom view (c) and a schematic rear view (d) of the spiralforming dice combined as the wire processing device, and show positionsof the spiral forming dice further rotated from the positions shown inFIG. 7 through 90°.

FIG. 9 are a schematic plan view (a), a schematic front view (b), aschematic bottom view (c) and a schematic rear view (d) of the spiralforming dice combined as the wire processing device, and show positionsof the spiral forming dice further rotated from the positions shown inFIG. 8 through 90°.

FIG. 10 are a schematic plan view (a), a schematic front view (b), aschematic bottom view (c) and a schematic rear view (d) of the spiralforming dice combined as the wire processing device, and show positionsof the spiral forming dice further rotated from the positions shown inFIG. 9 through 90°.

FIG. 11 are a schematic plan view (a), a schematic front view (b), aschematic bottom view (c) and a schematic rear view (d) of the spiralforming dice combined as the wire processing device, and show positionsof the spiral forming dice further rotated from the positions shown inFIG. 10 through 90°.

FIG. 12 are a schematic plan view (a), a schematic front view (b), aschematic bottom view (c) and a schematic rear view (d) of the spiralforming dice combined as the wire processing device, and show positionsof the spiral forming dice further rotated from the positions shown inFIG. 11 through 90°.

FIG. 13 are a schematic plan view (a), a schematic front view (b), aschematic bottom view (c) and a schematic rear view (d) of the spiralforming dice combined as the wire processing device, and show a statewhere a switching part is pulled out at the positions shown in FIG. 11.

FIG. 14 is a front view of an essential structure of a wire sending-outdevice.

FIG. 15 is a front view showing a structure of the wire processingdevice.

FIG. 16 is a right side view showing the structure of the wireprocessing device.

FIG. 17 is a transverse sectional plan view taken along the lineXVII-XVII in FIG. 16.

FIG. 18 is a perspective view of an essential portion showing a pair ofinduction arc faces of a spiral forming guide provided on a rotatingspiral forming die.

FIG. 19 is a time chart showing an operation of the rotating spiralforming dice and wire sending-out device.

FIG. 20 is an explanatory diagram showing a Z-winding spiral formingstate and an S-winding spiral forming state by the spiral forming dicecombined as the wire processing device.

FIG. 21 is a perspective view of a cable hanger in which a Z-windingspiral and an S-winding spiral are alternately and continuously formedalong an axis through the switching part.

FIG. 22 is an explanatory diagram of the cable hanger shown in FIG. 21as viewed from the axial direction.

FIG. 23 is an explanatory diagram of a state where one of winder flangesof a winder drum is removed.

BEST MODE FOR CARRYING OUT THE INVENTION

Embodiments of the present invention will be explained with reference tothe drawings.

FIG. 1 is a schematic plan view showing the entire structure of a cablehanger production system according to the present invention. The cablehanger production system 1 produces a cable hanger in which a Z-windingspiral and an S-winding spiral are alternately and continuously formedvia a switching part along an axis.

The cable hanger production system 1 includes a wire supply device 40and a wire processing device 10 disposed along a sending-out directionof a hanger wire 3 in this order from the front side. A cable hanger 5which is processed and completed by the wire processing device 10 isreeled up around a winder device (winder drum) 72.

An outline of a spiral forming operation carried out by the wireprocessing device 10 will be explained with reference to FIGS. 2 to 13.

The wire processing device 10 provides a housing 11 having a cylindricalspace 12 (see FIG. 5( c)). The hanger wire 3 is supplied from one end ofthe housing 11 and is sent out from the other end thereof. A pluralityof spiral forming dice 20 are accommodated in the space 12 adjacent toeach other such that they can rotate independently from each other.

At least three spiral forming dice 20 are required. Four spiral formingdice 20 (20 a, 20 b, 20 c, 20 d) will be explained here. That is, afirst spiral forming die 20 a, a second spiral forming die 20 b, a thirdspiral forming die 20 c and a fourth spiral forming die 20 d as countedfrom a hanger wire supply end of the housing 11 are used.

The first spiral forming die 20 a is a stationary die fixed to thehousing 11, and the second to fourth spiral forming dice 20 b, 20 c, and20 d are rotating dice supported around the axis such that they canrotate independently from each other.

The spiral forming dice 20 (20 a, 20 b, 20 c, 20 d) respectively includebottom faces 21 (21 a, 21 b, 21 c, 21 d) each forming a shapecorresponding to a curvature of the spiral on a plane intersecting withthe axis at right angles.

The spiral forming dice 20 (20 a, 20 b, 20 c, 20 d) respectively includeZ-winding wall faces 22 (22 a, 22 b, 22 c, 22 d) for forming a shapecorresponding to a pitch of a Z-winding spiral which is inclined withrespect to the plane, and S-winding wall faces 23 (23 a, 23 b, 23 c, 23d) for forming a shape corresponding to a pitch of an S-winding spiral.

In the second to fourth spiral forming dice 20 b, 20 c, and 20 d, theZ-winding wall faces 22 b, 22 c, and 22 d and the S-winding wall faces23 b, 23 c, and 23 d intersect with each other at a central portions ofthe second to fourth spiral forming dice 20 b, 20 c, and 20 d in thelongitudinal direction. Regions sandwiched between the Z-winding wallfaces 22 b, 22 c, and 22 d and the S-winding wall faces 23 b, 23 c, and23 d in front of and behind the intersections 24 b, 24 c, and 24 d areconstituted by bottom faces 21 b, 21 c, and 21 d.

In the case of the first spiral forming die 20 a, in the right half ofthe drawing, like the second to fourth spiral forming dice 20 b, 20 c,and 20 d, the Z-winding wall face 22 a and the S-winding wall face 23 aintersect with each other at the intersection 24 a. In the left half ofthe drawing of the spiral forming die 20 a, the Z-winding wall face 22 aand the S-winding wall face 23 a are not formed, an introduction portionextending in the axis is formed instead, and a left end of theintroduction portion in the drawing is a hanger wire introductionopening 26.

When the hanger wire 3 is inserted into the spiral forming dice 20 a, 20b, 20 c, and 20 d, the intersections 24 a, 24 b, 24 c, and 24 d of thespiral forming dice 20 a, 20 b, 20 c, and 20 d are positioned atlocations arranged along the axial direction (see FIG. 2( a) and FIG.5).

When the Z-winding spiral are formed, the Z-winding wall faces 22 a, 22b, 22 c, and 22 d of the spiral forming dice 20 a, 20 b, 20 c, and 20 dare positioned at locations which are sequentially connected to eachother (see FIG. 2( d) and FIG. 6).

When the S-winding spiral are formed, the S-winding wall faces 23 a, 23b, 23 c, and 23 d of the spiral forming dice 20 a, 20 b, 20 c, and 20 dare positioned at locations which are sequentially connected to eachother (see FIG. 13).

The positioning operation of the spiral forming dice 20 a, 20 b, 20 c,and 20 d at the forming positions of the Z-winding spiral from theinserting positions of the hanger wire 3 is carried out bysimultaneously rotating the second and subsequent spiral forming dice 20b, 20 c, and 20 d with respect to the spiral forming die 20 a as areference, and by sequentially stopping the second to fourth spiralforming dice 20 b, 20 c, and 20 d from the front side (see FIGS. 2( a)to (d)).

Although not shown in the drawings, the spiral forming dice 20 a, 20 b,20 c, and 20 d are positioned at the forming positions of the S-windingspiral from the inserting positions of the hanger wire 3 in the samemanner as that of the Z-winding spiral.

The second and subsequent spiral forming dice 20 b, 20 c, and 20 d areshifted from the forming positions of the Z-winding or S-winding spiralto the forming positions of the S-winding or Z-winding spiral when theswitching part 25 is formed and then, the second to fourth spiralforming dice 20 b, 20 c, and 20 d are positioned.

The position shifting operation of the spiral forming dice 20 a, 20 b,20 c, and 20 d from the forming positions of the Z-winding spiral to theforming positions of S-winding spiral is carried out by simultaneouslyrotating the second and subsequent spiral forming dice 20 b, 20 c, and20 d with respect to the reference first spiral forming die 20 a, and bysequentially stopping the spiral forming dice 20 b, 20 c, and 20 d fromthe front side (see FIGS. 7 to 12).

Although not shown in the drawings, the position shifting operation ofthe spiral forming dice 20 a, 20 b, 20 c, and 20 d from the formingpositions of the S-winding spiral to the forming positions of theZ-winding spiral is carried out in the same manner as the positionshifting operation from the Z-winding spiral to the S-winding spiral.

The rotation velocities of the second and subsequent spiral forming dice20 b, 20 c, and 20 d are set to such values that the spiral forming dice20 b, 20 c, and 20 d rotate through a rotation angle that is necessaryto shift from the forming positions of the Z-winding or S-winding spiralto the forming positions of the S-winding or Z-winding spiral while thehanger wire 3 moves from front ends to rear ends of the spiral formingdice 20 b, 20 c, and 20 d (see FIGS. 7 to 12). At this time, therotation velocities of the spiral forming dice 20 b, 20 c, and 20 d areuniform velocities.

A method for forming an S-winding spiral after a Z-winding spiral woundby predetermined times as shown in FIG. 2 will be explained here. FIG. 6show states where the spiral forming dice 20 a, 20 b, 20 c, and 20 d arein the Z-winding spiral forming positions.

The spiral forming dice 20 b, 20 c, and 20 d which can rotate arerotated leftward from the positions shown in FIG. 6 simultaneously atuniform velocities. FIG. 7 show positions after the dice start androtate through 90°. At this time, the bottom face 21 a of the spiralforming die 20 a and the bottom face 21 b of the spiral forming die 20 bface each other. The hanger wire 3 is sent along an axis through acentral portion of the opposed bottom faces 21 a and 21 b.

FIG. 8 show positions after the dice further rotate through 90° (180°after the starting position). At this time, the S-winding wall face 23 aof the spiral forming die 20 a and the S-winding wall face 23 b of thespiral forming die 20 b are connected to each other. At this position,the second spiral forming die 20 b is stopped. The hanger wire 3 islocated along the Z-winding wall faces 22 b, 22 c, and 22 d on the rightside from the intersection 24 b of the second spiral forming die 20 b,and is located along the S-winding wall faces 23 a and 23 b on the leftside from the intersection 24 b. With this configuration, the switchingpart 25 is formed in the intersection 24 b of the second spiral formingdie 20 b.

FIG. 9 show positions after the dice further rotate through 90 (270°after the starting position). At this time, the bottom face 21 b of thespiral forming die 20 b and the bottom face 21 c of the spiral formingdie 20 c face each other. The hanger wire 3 is sent until the switchingpart 25 is located at an upper end in the drawing in a boundary betweenthe opposed bottom faces 21 b and 21 c.

FIG. 10 show positions after the dice further rotate through 90° (360°after the starting position). At this time, the S-winding wall faces 23a and 23 b of the spiral forming dice 20 a and 20 b and the S-windingwall face 23 c of the spiral forming die 20 c are connected to eachother. In this position, the spiral forming die 20 c is stopped. Thehanger wire 3 is sent until the switching part 25 reaches theintersection 24 c of the spiral forming die 20 c.

FIG. 11 show positions after the dice further rotate through 90° (450°after the starting position). At this time, the bottom face 21 c of thespiral forming die 20 c and the bottom face 21 d of the spiral formingdie 20 d face each other. The hanger wire 3 is sent until the switchingpart 25 reaches the upper end in the drawing in the boundary between theopposed bottom faces 21 c and 21 d.

FIG. 12 show positions after the dice further rotate through 90° (540°after the starting position). At this time, the S-winding wall faces 23a, 23 b, and 23 c of the spiral forming dice 20 a, 20 b, and 20 c areconnected to the S-winding wall face 23 d of the spiral forming die 20d. The spiral forming die 20 d is stopped at this position. The hangerwire 3 is sent until the switching part 25 reaches the intersection 24 dof the spiral forming die 20 d.

Lastly, the switching part 25 of the hanger wire 3 passes through theright end position of the bottom face 21 d of the spiral forming die 20d and comes out from the wire processing device 10 (see FIG. 13).

The cable hanger 5 is produced in the following manner. First, thespiral forming dice 20 (20 a, 20 b, 20 c, 20 d) are positioned atlocations where the intersections 24 (24 a, 24 b, 24 c, 24 d) arearranged along the axial direction, and the hanger wire 3 is insertedinto the spiral forming dice 20 (20 a, 20 b, 20 c, 20 d) along theintersections 24 (24 a, 24 b, 24 c, 24 d) from the hanger wireintroduction opening 26 (see FIGS. 2( a) and 5).

Next, the hanger wire 3 is supplied from the hanger wire introductionopening 26 and in this state, the spiral forming dice 20 (20 a, 20 b, 20c, 20 d) are positioned at locations where the Z-winding or S-windingwall faces are sequentially connected to each other (see FIGS. 2( d) and6).

Next, the hanger wire 3 is supplied from the hanger wire introductionopening 26 and a state where the spiral forming dice 20 (20 a, 20 b, 20c, 20 d) are positioned is maintained, and the Z-winding or S-windingspiral which is wound by predetermined times is formed (see FIGS. 2( d)and 6).

Next, the hanger wire 3 is supplied from the hanger wire introductionopening 26 and in this state, the spiral forming dice 20 (20 a, 20 b, 20c, 20 d) are shifted to positions where the S-winding or Z-winding wallfaces are sequentially connected to each other and positioned (see FIGS.7 to 12).

Next, the hanger wire 3 is supplied from the hanger wire introductionopening 26 and a state where the spiral forming dice 20 (20 a, 20 b, 20c, 20 d) are positioned is maintained, and the S-winding or Z-windingspiral which is wound by predetermined times is formed (see FIG. 13).

The above operations are then repeated by predetermined times.

In the explanations of FIGS. 5 to 13, the spiral forming dice 20 a, 20b, 20 c, and 20 d are sequentially deviated from one another through 90°and the Z-winding wall faces 22 a, 22 b, 22 c, and 22 d or the S-windingwall faces 23 a, 23 b, 23 c, and 23 d are sequentially connected to eachother, but the invention is not limited to this structure. That is, thespiral forming dice 20 a, 20 b, 20 c, and 20 d can be deviated throughany angle other than 90°, e.g., through angle θ, and the Z-winding wallfaces 22 a, 22 b, 22 c, and 22 d or the S-winding wall faces 23 a, 23 b,23 c, and 23 d can be sequentially connected to each other.

In the explanations of FIGS. 5 to 13, the first spiral forming die 20 ais the stationary die and the second to fourth spiral forming dice 20 b,20 c, and 20 d are the rotating dice but the invention is not limited tothis. That is, the structure is not limited only if the first to fourthspiral forming dice 20 a, 20 b, 20 c, and 20 d are deviated from oneanother by 90° (or angle θ) in one direction when the Z-winding spiralis formed and the spiral forming dice 20 a, 20 b, 20 c, and 20 d aredeviated from one another in the other direction by 90° (or angle θ)when the S-winding spiral is formed. With this configuration, if thereis no problem in keep supplying the hanger wire 3 from the hanger wireintroduction opening 26, the first spiral forming die 20 a can be therotating die. In this case, the second spiral forming die 20 b, forexample, can be the stationary die.

Next, a specific structure of each part of the cable hanger productionsystem 1 will be explained. The cable hanger production system 1includes the wire supply device (wire sending-out device) 40 and thewire processing device 10.

The wire sending-out device 40 forcibly sends the hanger wire 3 which iscontinuously sent out from a wire drum (not shown) toward the wireprocessing device 10 through a wire guide 60. As shown in FIG. 14, thewire sending-out device 40 includes a stationary upper sending-out belt41 and a vertically movable lower sending-out belt 51 disposed below theupper sending-out belt 41 such as to be opposed thereto.

The stationary upper sending-out belt 41 is wound around a rear (rightin the drawing) belt rolling ring 42 in the sending-out direction movingfrom left to right in FIG. 14 and a front belt rolling ring (not shown)in an endless manner. A chain 47 wound around a driving sprocket 46 anda follower sprocket (not shown) supported by a base frame 45 is disposedbetween the rear belt rolling ring 42 and the front rolling ring. Thechain 47 is provided with a support plate 48. As the support plate 48moves, the sending-out belt 41 is rotated.

The vertically movable lower sending-out belt 51 is wound around a rear(right in the drawing) belt rolling ring 52 and a front belt rollingring in an endless manner. A chain 57 wound around a driving sprocket 56and a follower sprocket (not shown) supported by a movable frame 55 isdisposed between the rear belt rolling ring 52 and the front beltrolling ring. The movable frame 55 is vertically moved by a verticallymoving hydraulic device 54. The hydraulic device 54 includes a piston 54a and a cylinder 54 b. The chain 57 is provided with a support plate 58.As the support plate 58 moves, the sending-out belt 51 is rotated.

A driving motor 49 which drives the driving sprocket 46 of the uppersending-out belt 41, a driving motor 59 which drives a driving sprocket56 of the lower sending-out belt 51 and the hydraulic device 54 whichvertically moves the lower sending-out belt 51 are controlled based oncommands from a control device 65. When the lower sending-out belt 51 isin the lifted position (ON position) by the lifting operation of thehydraulic device 54, the lower sending-out belt 51 is crimped onto theupper sending-out belt 41 under pressure. At this time, the crimpingfaces of the sending-out belts 41 and 51 are supported by the supportplates 48 and 58, and effect for strongly sandwiching the hanger wire 3from above and below is generated. With this configuration, asandwiching face 50 which is long in the longitudinal direction issecured, and the hanger wire 3 can be strongly and reliably sent out bythe long sandwiching face 50 (in the direction of arrow A in FIG. 14).

The wire guide 60 is formed into a cylindrical shape in which the hangerwire 3 can be guided, and the wire guide 60 is supported by a guide base61. A front end of the wire guide 60 is located adjacent to a sendingout opening of the wire sending-out device 40. A rear end of the wireguide 60 is located adjacent to the hanger wire introduction opening 26of the wire processing device 10. The wire guide 60 reliably guides thehanger wire 3 such that the hanger wire 3 which is forcibly sent outfrom the wire sending-out device 40 is not bent between the sending outopening and the hanger wire introduction opening 26 by a strong slidingresistance generated when the hanger wire 3 is sent into the wireprocessing device 10.

The first to third rotating dice 20 b, 20 c, and 20 d are respectivelyfor guiding the spiral up to 90°, for guiding the spiral up to 180° andfor guiding the spiral up to 270°.

As shown in FIGS. 16, 17, and 18, the first rotating die 20 b isprovided at its outer peripheral face with a spiral forming guide 31 anda ring-like meshing gear 34. The first rotating die 20 b having thespiral forming guide 31 and the meshing gear 34 are rotatably supportedby a bearing 35 with respect to the die housing 11. The meshing gear 34is in mesh with a first driving gear 36 through an opening (not shown)formed in the die housing 11.

The spiral forming guide 31 is a combination of a pair of opposedinclined guide faces 32 which incline forward, and a pair of opposedinduction arc faces 33 provided inside the inclined guide faces 32.

In FIG. 18, when the induction arc faces 33 and the inclined guide faces32 are rotated in the direction of the arrow B and the hanger wire 9 issent out as shown with the arrow C, the induction arc faces 33 and theinclined guide faces 32 form the spiral form.

In this case, the inclined guide faces 32 of the first rotating die 20 bwhich can form the switching part (inverting part) 25 of the cablehanger 5 forms a shape which raises the switching part (inverting part)25 outside the arc region as shown in FIG. 22.

Meanwhile, the meshing gear 34 meshes with the first driving gear 36 towhich a rotation force is applied by a first die driving motor M1 whichcan rotate normally and reversely. The rotation force from the first diedriving motor M1 is transmitted to the first rotating die 20 b throughthe first driving gear 36 and the meshing gear 34, and the firstrotating die 20 b is rotated normally or reversely.

The second and third rotating dice 20 c and 20 d have the same structureas that of the first rotating die 20 b. Normal and reversed rotationforce is given to the second rotating die 20 c by a second die drivingmotor M2, and normal and reversed rotation force is given to the thirdrotating die 20 d by a third die driving motor M3.

The die housings 11 of the first to third rotating dice 20 b, 20 c, and20 d are disposed on the same axis X with respect to the base housing15.

The die driving motors M1, M2, and M3 of the first to third rotatingdice 20 b, 20 c, and 20 d are controlled based on commands from thecontrol device 65.

The control device 65 outputs operation commands to the first to thirdrotating dice 20 b, 20 c, and 20 d and the wire sending-out device 40based on a preset program. FIG. 19 shows such a relationship.

FIG. 19 is a time chart showing a relation between normal and reverserotations of the first to third rotating dice 20 b, 20 c, and 20 d andON and OFF of the wire sending-out device 40.

That is, the first to third rotating dice 20 b, 20 c, and 20 d normallyrotate respectively through 90°, 180°, and 270° under a condition that astate where the spiral forming guides 31 are arranged on the same axis Xas that of the hanger wire introduction opening 26 is defined as 0°.Next, the first to third rotating dice 20 b, 20 c, and 20 d rotate inthe opposite side (reversely rotate) beyond 0° at which the first tothird rotating dice 20 b, 20 c, and 20 d are arranged on the same axisX. The first to third rotating dice 20 b, 20 c, and 20 d alternatelyrepeat the normal rotation and reverse rotation.

This will be specifically explained based a definition that rightwardrotation is called plus side and leftward rotation is called minus side.

The first rotating die 20 b starts from 0° and (normally) rotatesrightward (plus side) by +90°. Next, the first rotating die 20 b returnsfrom the position of +90° to 0° and (reversely) rotates leftward (minusside) by −90°. The first rotating die 20 b then returns from theposition of −90° to 0° and again (normally) rotates rightward (plusside) by +90°. The first rotating die 20 b repeats these operationsalternately.

The second rotating die 20 c starts from 0° and (normally) rotatesrightward (plus side) by +180°. Next, the second rotating die 20 creturns from the position of +180° to 0° and (reversely) rotatesleftward (minus side) by −180°. The second rotating die 20 c thenreturns from the position of −180° to 0° and again (normally) rotatesrightward (plus side) by +180°. The second rotating die 20 c repeatsthese operations alternately.

The third rotating die 20 d starts from 0° and (normally) rotatesrightward (plus side) by +270°. Next, the third rotating die 20 dreturns from the position of +270° to 0° and (reversely) rotatesleftward (minus side) by −270°. The third rotating die 20 d then returnsfrom the position of −270° to 0° and again (normally) rotates rightward(plus side) by +270°. The third rotating die 20 d repeats theseoperations alternately.

On the other hand, the wire sending-out device 40 is once turned ON(crimping and sending out state) at the start position, and the ON stateis continued for a constant time even after rotating operations of thefirst to third rotating dice 20 b, 20 c, and 20 d by 90°, 180°, and 270°are completed. The wire sending-out device 40 is turned OFF and then, isagain brought into the ON state (crimping and sending out state). Thewire sending-out device 40 repeats the ON and OFF operations.

A relationship between the wire sending-out device 40 and the first tothird rotating dice 20 b, 20 c, and 20 d at the time will be explainedwith reference to FIG. 20.

In an ON region where the wire sending-out device 40 is turned ON(crimping and sending out state) simultaneously with start, the first tothird rotating dice 20 b, 20 c, and 20 d (normally) rotate to positionsof +90°, +180°, and +270°, respectively. With this configuration,right-handed spiral guide R-G to 270° is formed by spiral forming guides31 of the first to third rotating dice 20 b, 20 c, and 20 d as shown inFIG. 20. By forcibly sending the hanger wire 3 along the right-handedspiral guide R-G, a right-handed spiral portion 5-R having apredetermined number of windings is obtained.

In a next ON region where the wire sending-out device 40 is once turnedOFF and is again turned ON (crimping and sending out state), the firstto third rotating dice 20 b, 20 c, and 20 d (reversely) rotate topositions of −90°, −180°, and −270°, respectively. With thisconfiguration, a left-handed spiral guide L-G to 270° is formed byspiral forming guides 31 of the first to third rotating dice 20 b, 20 c,and 20 d as shown in FIG. 20. By forcibly sending the hanger wire 3along the left-handed spiral guide L-G, a left-handed spiral portion 5-Lhaving a predetermined number of windings is obtained.

Although the right-handed rotation of the first to third rotating dice20 b, 20 c, and 20 d is defined as normal rotation and the left-handedrotation thereof is defined as reverse rotation in the aboveexplanations, left-handed rotation can be defined as normal rotation andright-handed rotation can be defined as reverse rotation. To form smoothspiral guides, four combined dice including the stationary die 20 a andthe first to third rotating dice 20 b, 20 c, and 20 d is employed in theabove explanations. However, three combined dice including thestationary die 20 a and the first and second rotating dice 20 b and 20 ccan also be employed.

The wire sending-out device 40 is in a state where the movablesending-out belt 51 is lowered with respect to the stationarysending-out belt 41 in the OFF region, and the sandwiching state of thehanger wire 3 is released. This OFF period is 1 to 2 seconds. With thisconfiguration, when the hanger wire 3 enters into the next left-handedspiral portion 5-L from the right-handed spiral portion 5-R, thesandwiched state of the hanger wire 3 can be released temporarily, andtorsion reaction force can be released temporarily.

The wire sending-out device 40 can also alternately and continuouslyform the right-handed spiral portion 5-R and the left-handed spiralportion 5-L even without providing the OFF period in which thesandwiching state of the hanger wire 3 is released and in the ON state(crimping and sending out state) in which the sending out operation iscontinued. Even when the number of windings of the right-handed spiralportion 5-R and the number of windings of the left-handed spiral portion5-L are relatively small as about 2.0 windings (about 1.5 to 2.5windings), it is possible to produce the cable hanger 5 having asufficient quality.

A cable hanger taking-out device 70 includes a cable hanger supportmember 71 having a predetermined length provided on the third rotatingdie 20 d, and a winder drum 72 which reels up the cable hanger 5 as aproduct.

The cable hanger support member 71 is formed into a cylindrical shapewhich is integrally mounted on a central shaft of the third rotating die20 d, and rotates integrally with the third rotating die 20 d.Therefore, the cable hanger 5 sent out from the third rotating die 20 dis supported by the cable hanger support member 71 over a predeterminedlength without falling on the ground and then, the cable hanger 5 isreeled up around the winder drum 72.

The winder drum 72 includes a pair of left and right winder flanges 73,a winder barrel 74 located between the winder flanges 73, and aplurality of projecting portions 75 formed on a periphery of the winderbarrel 74 at predetermined distances from one another in the radialdirection. The projecting portions 75 project radially outward oversubstantially entire length of the winder barrel 74. When the cablehanger 5 is reeled up around the winder barrel 74 of the winder drum 72,the right-handed spiral portion 5-R or the left-handed spiral portion5-L is extended in a corrugate form as shown in FIG. 23 and the cablehanger 5 is reeled up in an unstable state. At this time, if theswitching part (inverting part) 25 located at junction between theright-handed spiral portion 5-R and the left-handed spiral portion 5-Lis locked to the projecting portions 75, the cable hanger 5 can bestabilized and reliably reeled up.

One of the left and right winder flanges 73 is detachably mounted on thewinder barrel 74. When the winder flange 73 is detached, the winderbarrel 74 is exposed and the cable hanger 5 can easily be detached fromthe winder barrel 74.

A production method of the cable hanger 5 by the cable hanger productionsystem 1 will be explained. First, as shown in FIG. 1, the spiralforming guides 31 of the first to third rotating dice 20 b, 20 c, and 20d are set on the same axis X as the hanger wire introduction opening 26.The hanger wire 3 which is continuous in the longitudinal direction isinserted into the spiral forming guides 31 from the hanger wireintroduction opening 26. Next, the wire sending-out device 40 is broughtinto the ON state, the hanger wire 3 is sent out and at the same time,the first to third rotating dice 20 b, 20 c, and 20 d are rotatedrightward to the positions of +90°, +180°, and +270°, respectively. Withthis configuration, the hanger wire 3 forms the right-handed spiral upto 270°. At this time, the right-handed spiral guide R-G is formed bythe first to third rotating dice 20 b, 20 c, and 20 d. Therefore, theright-handed spiral portion 5-R having a predetermined number ofwindings can be obtained by forcibly keeping sending the hanger wire 3continuously for a constant time.

Next, the sandwiching state of the hanger wire 3 is temporarily releasedand the torsion reaction force is released. The hanger wire 3 is againsent out, and at the same time, the first to third rotating dice 20 b,20 c, and 20 d are rotated leftward to positions of −90°, −180°, and−270° beyond 0°, respectively. With this configuration, the hanger wire3 forms the left-handed spiral until 270° through the switching part(inverting part) 25. At this time, the left-handed spiral guide L-G isformed by the first to third rotating dice 20 b, 20 c, and 20 d.Therefore, the left-handed spiral portion 5-L having a predeterminednumber of windings can be obtained by forcibly keeping sending thehanger wire 3 continuously for a constant time.

By repeating the above operations, the cable hanger 5 in which theright-handed spiral portion 5-R and the left-handed spiral portion 5-Lare alternately continued along the axial direction through theswitching part (inverting part) 25 can be obtained as shown in FIG. 21.

At the time of the series of spiral forming operation, strong slidingresistance is created in the hanger wire 3 by the spiral forming guides31 when the hanger wire 3 is sent out by the wire sending-out device 40.However, because the hanger wire 3 is guided by the wire guide 60 fromthe wire sending-out device 40 to the hanger wire introduction opening26, the hanger wire 3 can smoothly be sent out reliably without beingbent.

In this case, it is preferable to provide the hanger wire introductionopening 26 with an oil reservoir to reduce the sliding resistance, andto create the lubricating effect in the hanger wire 3 to reduce theinsertion resistance.

INDUSTRIAL APPLICABILITY

The present invention provides a production system for producing a cablehanger in which a Z-winding spiral and an S-winding spiral arealternately and continuously formed along an axis via a switching part.A hanger wire is supplied from one end of a housing and sent out fromthe other end thereof. A plurality of spiral forming dice areaccommodated in a cylindrical space in the housing such that the spiralforming dice are adjacent to each other and can rotate independentlyfrom each other. Each spiral forming die includes a bottom face forminga shape corresponding to a curvature of a spiral on a plane intersectingwith an axis at right angles between an inner peripheral face of thehousing and the bottom face, a Z-winding wall face forming a shapecorresponding to a pitch of the Z-winding spiral inclined with respectto the plane, and an S-winding wall face forming a shape correspondingto a pitch of the S-winding spiral. The Z-winding wall face and theS-winding wall face intersect with each other at a central portion ofthe spiral forming die in its longitudinal direction. A regionsandwiched between the Z-winding wall face and the S-winding wall faceis constituted by the bottom face in front of and behind theintersection. Using the hanger wire, the Z-winding spiral and S-windingspiral can be formed alternately and continuously.

The invention claimed is:
 1. A cable hanger production system in which aZ-winding spiral and an S-winding spiral are alternately andcontinuously formed along an axis via a switching part, comprising ahousing having a cylindrical space in which a hanger wire is suppliedfrom one end of the housing and the hanger wire is sent out from theother end thereof, and a plurality of spiral forming dice which areaccommodated in the cylindrical space of the housing such that thespiral forming dice are adjacent to each other and configured to rotateindependently from one another, wherein each of the spiral forming diceincludes a bottom face forming a shape corresponding to a curvature of aspiral on a plane intersecting with the axis at right angles between aninner peripheral face of the housing and the bottom face, a Z-windingwall face forming a shape corresponding to a pitch of the Z-windingspiral which is inclined with respect to the plane, and an S-windingwall face forming a shape corresponding to a pitch of the S-windingspiral, the Z-winding wall face and the S-winding wall face intersectwith each other at a central portion of the spiral forming die in alongitudinal direction thereof, and a region sandwiched between theZ-winding wall face and the S-winding wall face is constituted by thebottom face.
 2. The cable hanger production system according to claim 1,wherein when the hanger wire is inserted, the intersections of thespiral forming dice are positioned at locations arranged along the axialdirection.
 3. The cable hanger production system according to claim 1,wherein when the Z-winding spiral or S-winding spiral is formed, theZ-winding wall faces or the S-winding wall faces of the spiral formingdice are sequentially positioned at locations which are connected toeach other.
 4. The cable hanger production system according to claim 3,wherein a positioning operation of the spiral forming dice at formingpositions of the Z-winding spiral or S-winding spiral from the insertingpositions of the hanger wire is carried out by simultaneously rotatingthe plurality of second and subsequent spiral forming dice with respectto the first spiral forming die as a reference as counted from a hangerwire supply end of the housing, and by stopping the spiral forming dicein the order from a front side.
 5. The cable hanger production systemaccording to claim 3, wherein the spiral forming dice are positioned byshifting from the forming positions of the Z-winding spiral or S-windingspiral to the forming positions of the S-winding spiral or Z-windingspiral when the switching part is formed.
 6. The cable hanger productionsystem according to claim 5, wherein position shifting operation of thespiral forming dice from the forming positions of the Z-winding spiralor S-winding spiral to the forming positions of the S-winding spiral orZ-winding spiral is carried out by simultaneously rotating the pluralityof second and subsequent spiral forming dice with respect to the firstspiral forming die as a reference as counted from a hanger wire supplyend of the housing, and by stopping the spiral forming dice in the orderfrom a front side.
 7. The cable hanger production system according toclaim 4, wherein rotation velocities of the spiral forming dice are setto such a value that each spiral forming die rotates through a rotationangle required for shifting from the forming position of the Z-windingspiral or S-winding spiral to the forming position of the S-windingspiral or Z-winding spiral while the hanger wire moves from a front endto a rear end of the spiral forming dice.
 8. The cable hanger productionsystem according to claim 1, wherein the rotation velocities of thespiral forming dice are uniform velocities.
 9. The cable hangerproduction system according to claim 1, wherein the first spiral formingdie as counted from the hanger wire supply end of the housing is fixed,and second and subsequent spiral forming dice are rotated.
 10. The cablehanger production system according to claim 1, wherein at least threespiral forming dice are required.
 11. The cable hanger production systemaccording to claim 2, wherein the Z-winding spiral or S-winding spiralis formed, the Z-winding wall faces or the S-winding wall faces of thespiral forming dice are sequentially positioned at locations which areconnected to each other.
 12. The cable hanger production method systemaccording to claim 11, wherein a positioning operation of the spiralforming dice at forming positions of the Z-winding spiral or S-windingspiral from the inserting positions of the hanger wire is carried out bysimultaneously rotating the plurality of second and subsequent spiralforming dice with respect to the first spiral forming die as a referenceas counted from a hanger wire supply end of the housing, and by stoppingthe spiral forming dice in the order from a front side.
 13. The cablehanger production system according to claim 11, wherein the spiralforming dice are positioned by shifting from the forming positions ofthe Z-winding spiral or S-winding spiral to the forming positions of theS-winding spiral or Z-winding spiral when the switching part is formed.14. The cable hanger production system according to claim 13, whereinposition shifting operation of the spiral forming dice from the formingpositions of the Z-winding spiral or S-winding spiral to the formingpositions of the S-winding spiral or Z-winding spiral is carried out bysimultaneously rotating the plurality of second and subsequent spiralforming dice with respect to the first spiral forming die as a referenceas counted from a hanger wire supply end of the housing, and by stoppingthe spiral forming dice in the order from a front side.
 15. The cablehanger production system according to claim 6, wherein rotationvelocities of the spiral forming dice are set to such a value that eachspiral forming die rotates through a rotation angle required forshifting from the forming position of the Z-winding spiral or S-windingspiral to the forming position of the S-winding spiral or Z-windingspiral while the hanger wire moves from a front end to a rear end of thespiral forming dice.
 16. The cable hanger production system according toclaim 12, wherein rotation velocities of the spiral forming dice are setto such a value that each spiral forming die rotates through a rotationangle required for shifting from the forming position of the Z-windingspiral or S-winding spiral to the forming position of the S-windingspiral or Z-winding spiral while the hanger wire moves from a front endto a rear end of the spiral forming dice.
 17. The cable hangerproduction system according to claim 14, wherein rotation velocities ofthe spiral forming dice are set to such a value that each spiral formingdie rotates through a rotation angle required for shifting from theforming position of the Z-winding spiral or S-winding spiral to theforming position of the S-winding spiral or Z-winding spiral while thehanger wire moves from a front end to a rear end of the spiral formingdice.
 18. The cable hanger production system according to claim 4,wherein the rotation velocities of the spiral forming dice are uniformvelocities.
 19. The cable hanger production system according to claim12, wherein the rotation velocities of the spiral forming dice areuniform velocities.
 20. The cable hanger production system according toclaim 6, wherein the rotation velocities of the spiral forming dice areuniform velocities.
 21. The cable hanger production system according toclaim 14, wherein the rotation velocities of the spiral forming dice areuniform velocities.
 22. The cable hanger production system according toclaim 7, wherein the rotation velocities of the spiral forming dice areuniform velocities.
 23. The cable hanger production system according toclaim 15, wherein the rotation velocities of the spiral forming dice areuniform velocities.
 24. The cable hanger production system according toclaim 16, wherein the rotation velocities of the spiral forming dice areuniform velocities.
 25. The cable hanger production system according toclaim 17, wherein the rotation velocities of the spiral forming dice areuniform velocities.
 26. A cable hanger production system in which aZ-winding spiral and an S-winding spiral are alternately andcontinuously formed along an axis via a switching part, comprising awire processing device including a housing having a cylindrical space inwhich a hanger wire is supplied from one end of the housing and thehanger wire is sent out from the other end thereof, and a plurality ofspiral forming dice which are accommodated in the cylindrical space ofthe housing in adjacent to one another such that the spiral forming diceare configured to be rotated by a motor independently from each other;and a wire supply device which is disposed in front of the wireprocessing device for supplying the hanger wire toward the one end ofthe wire processing device; wherein the spiral forming dice arepositioned by shifting from positions for forming the Z-winding spiralor S-winding spiral to positions for forming the S-winding spiral orZ-winding spiral by simultaneously rotating second and subsequent spiralforming dice with respect to the first spiral forming die as a referenceas counted from the one end of the wire processing device, and bystopping the spiral forming dice in the order from a front side; androtation velocities of the spiral forming dice by the motor are set tosuch a value that the each spiral forming die rotates through a rotationangle required for shifting from the forming position of the Z-windingspiral or S-winding spiral to the forming position of the S-windingspiral or Z-winding spiral while the hanger wire supplied by the wiresupply device moves from a front end to a rear end of the spiral formingdice, wherein each of the spiral forming dice includes: a bottom faceforming a shape corresponding to a curvature of the spiral on a planeintersecting with the axis at right angles between inner peripheral faceof the housing and the bottom face; and a Z-winding wall face forming ashape corresponding to a pitch of the Z-winding spiral which is inclinedwith respect to the plane, and an S-winding wall face forming a shapecorresponding to a pitch of the S-winding spiral.
 27. A productionmethod for forming a cable hanger in which a Z-winding spiral and anS-winding spiral are alternately and continuously formed along an axisvia a switching part; wherein a hanger wire is supplied from one end ofa housing and sent out from the other end thereof, a plurality of spiralforming dice are accommodated in a cylindrical space of the housing suchthat the spiral forming dice are adjacent to each other and configuredto rotate independently from each other, the spiral forming dice areused; each of the spiral forming dice includes a bottom face forming ashape corresponding to a curvature of a spiral on a plane intersectingwith the axis at right angles between an inner peripheral face of thehousing and the bottom face, a Z-winding wall face forming a shapecorresponding to a pitch of the Z-winding spiral which is inclined withrespect to the plane, and an S-winding wall face forming a shapecorresponding to a pitch of the S-winding spiral, the Z-winding wallface and the S-winding wall face intersect with each other at a centralportion of the spiral forming die in a longitudinal direction thereof,and a region sandwiched between the Z-winding wall face and theS-winding wall face is constituted by the bottom face, in the method;after a first step of inserting the hanger wire along the intersectionsinto the spiral forming dice positioned at locations where theintersections are arranged along the axial direction is performed, thehanger wire is supplied from the one end and in this state, and secondto fifth steps are repeated by predetermined times; the second step ofpositioning the spiral forming dice at locations where the Z-windingwall faces or S-winding wall faces are sequentially connected to eachother; the third step of keeping the spiral forming dice in theirpositioned state and for forming the Z-winding spiral or S-windingspiral having a predetermined number of windings; the fourth step ofposition shifting the spiral forming dice to locations where theS-winding wall faces or Z-winding wall faces are sequentially connectedto each other; and the fifth step of keeping the spiral forming dice intheir positioned state and for forming the S-winding spiral or Z-windingspiral having a predetermined number of windings.
 28. The cable hangerproduction method according to claim 27, wherein the second step and thefourth step are carried out by simultaneously rotating second andsubsequent spiral forming dice with respect to the first spiral formingdie as a reference as counted from a hanger wire supply end of thehousing, and by stopping the spiral forming dice in the order from afront side.